Engineer's Handbook - M20

m
c
M20
Caterpillar confidential: yellow

m
Engineer ´s Handbook
M20 c
Table of Contents
Table of Contents .......................................................................... 2
Indikation ........................................................................................ 6
Data ................................................................................................. 7
- Engine data ........................................................................................................................... 7
- Engine operating data ........................................................................................................ 7
Engine Block .................................................................................. 8

- Tightening torques for screw plugs ............................................................................. 8
- Crank case cover ................................................................................................................ 8
Cylinder Head ................................................................................. 9

- Tightening torque ............................................................................................................... 9
- Tightening torques for screw plugs ............................................................................. 9
- Valve rocker bracket ........................................................................................................ 10
- Valve rocker (inlet and exhaust) .................................................................................... 11
- Setting of valve bridges and valve clearances ........................................................... 11
- Valve clearance values .................................................................................................... 12
- Valve guide ......................................................................................................................... 12
- The valve stems are used as specified below: ........................................................ 12
- Valve rotators .................................................................................................................... 12
- Guiding bolts for the valve bridges. ............................................................................. 13
- Sleeve for the fuel injecion valve .................................................................................. 13
- Fuel injection valve ........................................................................................................... 13
- Removal fuel injektion valve .......................................................................................... 14
- Exhaust gas manifold ....................................................................................................... 15
- Valve shaft machining ...................................................................................................... 16
- Deviations from true running valve shaft ................................................................... 17
- Fitting of valve seat rings ................................................................................................ 18
Piston ............................................................................................ 19
- Tightening torques Mahle 1.10.7-26.70.00-01 .............................................................. 19
- Tightening torques Mahle 1.10.7-26.70.00-02 / 03 / 04 / 05 ........................................ 19
- MHW 1.10.7-26.70.00-22 Fitting ........................................................................................ 20
- Kolbenschmidt 1.10.7-26.70.00-07 .................................................................................. 21
- Wear limit and clearances ............................................................................................... 21
- Piston rings gas oil operation ....................................................................................... 22
- Piston rings heavy fuel operation ................................................................................. 22
Edition Service Document of Page

11.11.2004 Caterpillar Motoren GmbH & Co. KG 2
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M20 c
Table of Contents
Connecting Rod ........................................................................... 23

- Big end bearing ................................................................................................................. 23
- Fitting of piston pin bush ................................................................................................ 23
- Maximum tolerance between piston pin and piston pin bush .............................. 23
- Measurement of the gap ................................................................................................ 24
- Reference dimension of the big end bearings after correct tightening ............. 24
Liner .............................................................................................. 25
- Nominal size Ø (original size) ........................................................................................ 25
- Wear limits .......................................................................................................................... 25
- Wedge shape ..................................................................................................................... 25
- Canyon ................................................................................................................................. 25
- Score .................................................................................................................................... 25
- Pocket .................................................................................................................................. 25
- Fire ring ............................................................................................................................... 26
- Dismounting of fire ring (without groove) .................................................................. 26
- Removal of the fire ring (with groove) ........................................................................ 27
- Mounting liner ................................................................................................................... 27
Crankshaft .................................................................................... 28
- Crankshaft bearing ........................................................................................................... 28
- Marking ............................................................................................................................... 29
- Located and normal main bearings .............................................................................. 29
- Measurement of the gap ................................................................................................ 29
- Crank web deflection ...................................................................................................... 30
- Counterweight .................................................................................................................. 30
Gear Train ..................................................................................... 31

- Gear wheel on crankshaft .............................................................................................. 31
- Mounting of crankshaft gear wheel ............................................................................. 32
- Intermediate gear wheel mounting ............................................................................. 33
- Lub. oil injectors for the gear drive .............................................................................. 34
- Backlash .............................................................................................................................. 34
- Intermediate gear wheel ................................................................................................ 34
- Camshaft gear wheel ...................................................................................................... 35
Governor Drive ............................................................................ 36

- Governor drive gear ......................................................................................................... 36
- Backlash .............................................................................................................................. 36
- End clearance ..................................................................................................................... 36

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M20 c
Table of Contents
Camshaft ....................................................................................... 37
- Camshaft bearing ............................................................................................................. 37
- Vibration damper for camshaft ..................................................................................... 37
- Tightening torques camshaft ........................................................................................ 38
- Mounting camshaft ........................................................................................................... 38
Lower Valve Drive ....................................................................... 39
Fuel Injection Pumps ................................................................... 40

- Injection pump 0.00.6-43.12.00-72 type: DSFP 1M ....................................................... 40
- Injection pump 0.00.6-43.12.00-79 type: DSFP 1MW .................................................... 41
- Injection pump 0.00.6-43.12.00-92 type: DSFP 1MW .................................................... 42
- Fuel distributing and collecting pipe ............................................................................ 43
- Fuel distributing pipe for fuel injection pump variants -79 and -92 ...................... 43
- Dismounting / mounting .................................................................................................. 44
- Check of commencement of fuel delivery ................................................................. 44
Sundries ....................................................................................... 45
- Regulating shaft ................................................................................................................ 45
- Fuel indicator ..................................................................................................................... 46
- Cooling water distributing pipe .................................................................................... 47
Opposite Side of Coupling ......................................................... 48

- With and without power take-off with vibration damper ........................................ 48
Pump Carrier ................................................................................ 49

- Pump carrier plate ............................................................................................................ 49
- Cooling water pump ........................................................................................................ 49
- Fuel feed pump ................................................................................................................. 49
- Lub. oil pump ..................................................................................................................... 49
- Pump mounting ................................................................................................................. 50
- Backlashes ......................................................................................................................... 50
Flywheel Mounting ...................................................................... 51

- Mounting - disassembly ................................................................................................. 51
- Gear rim on flywheel for pneumatic starter .............................................................. 51
- Flywheel variants .............................................................................................................. 52
Flexible Flange Connection ....................................................... 53

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M20 c
Table of Contents
Charge Air Cooler ........................................................................ 54

- Mounting ............................................................................................................................. 54
- Cleaning .............................................................................................................................. 55
- Dismounting ....................................................................................................................... 55
Exhaust Gas Manifold ................................................................. 56
Generator GP-Engine ................................................................. 57

- Attachment engine and generator ............................................................................... 57
- Sealing surfaces ............................................................................................................... 57
Flexible Mounting ........................................................................ 58

- Assembly ............................................................................................................................ 58
Firing Sequences - Valve Timing Values ................................... 61
Dimensions and Weights ............................................................ 62

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M20 c
Indikation
By constructional measures on the injection system and by simple and permanent setting
of the ignition timing and the fuel rack reading - already during assembly of the engine -
adjustment of the firing pressures during the test bed run can be avoided.
Therefore, firing pressures and compression pressures are not stated in the acceptance
test records.
On the occasion of checks and measuring trips later on indicating shall not be carried
out. Only in exceptional cases and only after consulting the technical service VT5 the
setting of the injection pumps may be changed.
The following values serve for judgment on possible failures:
1. Engine speed
2. Fuel rack reading
3. Lubricating oil t inlet engine t oil cooler inlet
4. Fresh water t inlet engine t outlet engine
t inlet charge air cooler t outlet charge air cooler
t outlet turbocharger
5. Charge air temperature t before cooler t before engine
6. Exhaust gas temperature t after cylinder t after turbocharger
7. Lub. oil pressure
8. Fresh water pressure
9. Charge air pressure after charge air cooler
10. Differential pressure at the charge air cooler

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M20 c
Data
- Engine data - Engine operating data
stroke = 300 mm temperatures
bore = 200 mm lub. oil
speed, rpm = 900 - 1000 engine inlet 60 - 65 ° C
main bearing temperature rise 10 - 14 ° C
inside Ø = 180 mm fresh water circulation cooling
outside Ø = 190 mm engine outlet 60 - 70 ° C
big end bearing temperature rise 6 - 12 ° C
inside Ø = 152 mm charge air
outside Ø = 161 mm engine inlet 45 - 60 ° C
valves, inlet and exhaust pressures
length = 336 mm lub. oil 4.0 - 4.5 bar
shaft Ø = 14.05 mm fresh water circulation cooling
valve head Ø = 66 mm with min. 4 mWs 2.5 - 6.0 bar
valve guide fuel pressure before injection

pumps
length = 175 mm
MDO-operation 3.0 - 5.0 bar
inside Ø = 14.14 mm
HDO-operation 4.0 - 5.0 bar
details for rated engine output and nominal

engine speed.
Numbers of teeth on camshaft gear wheel = 80 teeth.
N = (F x 60 x 2) / 60 (Rpm) F = (N x Z) / (2 x 60) (Hz)

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M20 c
Engine Block
- Tightening torques for screw plugs

Tighten screw plugs M14x1,5 with → M = 100 Nm
Tighten screw plugs M33x2 with → M = 200 Nm
- Crank case cover 1

Mount flat gaskets slightly greased.
Use Dirko, Nr.610.020 (Dirko, grey) for coverings
without any gasket.
Tighten the screws - 1 - for the

cover with blow-off valve
(new variation 1.10.7-16.33.00-05) with → M = 24,5 Nm

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M20 c
Cylinder Head
- Tightening torque
The tightening torque for inserting the tie bolts is → M = 300 Nm
Molykote
1. Tighten nuts with pin by hand.
2. Lengthen bolts with → P = 600 bar
and tighten nuts with pin by hand.
Molykote
The pressure must remain constant if the pump is not operated, otherwise faulty
tightening. check: Decrease pressure by 50 bar. Loosening the nuts must not be
possible any more.
Dismounting:
If the cylinder head nuts cannot be loosened with P = 600 bar, an
increase by 50bar is possible. Further pressure increase involves the risk that the
thread will expand and the nuts will jam.
At the control bore - 1 - leakages

between cylinder head, flame ring
and cooling water distributing
housing can be detected.
- Tightening torques for screw plugs

Hylomar
Hylomar
Rivolta G.W.F.
Tighten screw plugs G 1/2 A with → M = 60 Nm
Rivolta G.W.F.

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M20 c
Cylinder Head
- Valve rocker bracket

The tightening torque for inserting
the studs - 1 - is → M = 80 Nm
Oil
Tighten nuts - 2 - with → M = 120 Nm

Molykote
The tightening torque for inserting the studs - 3 - is → M = 40 Nm

Oil
Tighten nuts - 4 - with → M = 60 Nm

Molykote
1
2 2
3
4

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M20 c
Cylinder Head
- Valve rocker (inlet and exhaust)

Original size (bush + shaft) → 0.12 - 0.14 mm
Limit clearance (bush + shaft) → 0.20 mm
Reference size for the bush after pressing-in Ø → 49.99 + 0.109

mm
The bush shall recede after pressing-in by → 0.20 mm
Before pressing-in slightly coat the bushes with oil, Molykote must not be used. 1
When shrinking-in new ball pins by
supercooling attention must be paid to
the accurate position - 1 - in order to
Z
guarantee perfect oil supply.
(Supercooling to -195 ° C with Z
nitrogen)
0.20
- Setting of valve bridges and valve clearances

1. Turn out adjusting screws - 1 - of the valve rockers to 1
obtain a sufficient clearance.
2. Turn out adjusting screws - 2 - of the valve

bridges to obtain a clearance at „Y“ when
Valve rocker
valve bridge touches „X“.
3. Screw in adjusting screws - 2 - until the

valve bridges rest on the valves without
clearance.
4. Hold adjusting screws - 2 - fast and lock them.
5. Adjust valve clearance with adjusting screw - 1 -. Valve bridge

2 Oil supply
The valve bridges were modified.

On modern engines visual checks allow to Y X
ascertain if the valve bridge fits on the
valve stem.

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M20 c
Cylinder Head
- Valve clearance values

Setting under hot running conditions, abt. 15 min after stopping the engine.
inlet → 0.60 mm
exhaust → 0.80 mm
After repairs in cold engine condition:
inlet → 0.60 mm
exhaust → 0.65 mm
- Valve guide
inlet - exhaust
nominal clearance → 0.10 - 0.17 mm
limit clearance → 0.40 mm
nominal size outside Ø 26,033 - 0,01

over size outside Ø 27,033 - 0,01
Measure diameter of the valve shaft in the guide area. Measure guide in cross direction of
engine.
The valve guides are inserted in the cylinder head after cooling them down to -195 ° C
(liquid nitrogen)
- The valve stems are used as specified below:

inlet exhaust
HFO 1.10.7-22.10.01-01 / -03 / -07 1.10.7-22.10.01-02
MDO 1.10.7-22.10.01-01 / -03 / -07 1.10.7-22.10.01-05
From March 2001 on the inlet valve stem 1.10.7-22.10.01-07 is standard equipment for MDO and
HFO operation.
This valve stem has 20° -8´, the valve stems 1.10.7-22.10.01-01 and -03 have 30° -8´.
- Valve rotators
MDO - operation: only at the inlet valves
HFO - operation: at inlet and exhaust valves

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M20 c
Cylinder Head
- Guiding bolts for the valve bridges.

The tightening torque for the guiding bolts is → M = 150 Nm
(Thread M30x2) Loctite 243
The tightening torque for the guiding bolts is → M = 200 Nm
(Thread M36x2) Loctite 243
Oversize for repair purposes

Insert guiding bolts with Loctite 243
and provide the contact faces with
Molykote.
From cylinder head variation

1.10.3-21.51.00-06 insert guiding bolts
with a temperature -195°C (liquid nitrogen).
- Sleeve for the fuel injecion valve

Tighten the sleeve for the fuel injecion valve with → M = 100 Nm
Insert o-rings with liquid beef tallow or with

green soft soap in the right position.
Check that the sleeve
insertion of the cylinder head is free of burr
before mounting.
O-ring Viton, green
O-ring Perbunan
- Fuel injection valve

The tightening torque for inserting the studs is → M = 40 Nm
Oil
Pretighten nuts with → M = 55 Nm
and loosen again,
then tighten with → M = 30 Nm
Molykote
Tighten nozzle nut with → M = 250 - 20 Nm
Oil lubrication

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M20 c
Cylinder Head
- Removal fuel injektion valve

Loosen pressure screws - 1 - and - 2 -. Loosen transverse thrust piece - 3 - with cover
- 4 - by lever effect, then force radial thrust piece - 5 - out of its end position
(approximate 20 mm).
(Important, otherwise damages are inevitable.)
Unscrew nuts from the injection valve. Remove flange - 6 - and mount it again inversely
(180 °). Screw extractor - 7 - on adjusting screw - 8 - and loosen nozzle holder by
turning against the flange - 6 -. Withdraw the injection valve from the cylinder head.
5
4
1 3
2
6 - Sequence of installation
1. Insert injection valve, tighten acc. to specification,
and loosen it again.
2. Fit radial thrust piece - 5 - and transverse thrust

piece - 3 -.
3. First tighten pressure screw - 2 -, then pressure

screw - 1 - manually, then tighten pressure
screw - 2 - and after that pressure
screw - 1 - acc. to specification.
4. Tighten injection valve acc. to specification.

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M20 c
Cylinder Head
Tighten pressure screw - 1 - and - 2 -

with → M = 85 Nm
Tighten screws - 9 - for connecting

housing with → M = 35 Nm
Molykote
Screws M10x 55 ISO 4762
- Exhaust gas manifold M = 60 Nm

Tighten screws to cyl. head alternately.
1st step up to → M = 110 Nm
and
2nd step up to →
Rivolta G.W.F.

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M20 c
Cylinder Head
- Valve shaft machining

Grinding of inlet and exhaust valves
Apply small dots of the diamond paste Dp 30/
+0.1 -0.3
10-15 my with a syringe to the new or
Ø 62.5 -01
remachined valve cone and distribute the
Reference dimension 6.93

paste equally. Thereafter the seat ring Ø 59 -02
8´
surface is to be sprayed with a thinner (F25)
°-
belonging to the diamond paste, for dilution
30
and in order to increase the grip. Insert the
oiled valve stem into the guide bush. Fasten
the device at the valve head and grind the
4.71
valve face and seat by hand applying a Inlet valve
moderate pressure, rotating the device. The 1.10.7-2.10.01-
01; 03
contact reflection „a“ which is visible by the
smooth grinding process shall not exceed 30
% of the seat width starting from
the outside diameter. If the
+0.10
6.55 -0.30
bearing characteristics described Reference dimension Ø 62.5 -01
above are not reached, Ø 59 -02
remachining of both sealing
8´
Reference dimension
surfaces is necessary.
°-
20
After machining both seats
have to be checked with a
luminous magnifier. The 4.71
fillet must not be refinished.
Inlet valve
After machining round 1.10.7-22.10.01-07
off the outside edge with a stone.
The dimensions specified in the
sketch are to be observed.
Reference dimension
Ø 62.5 -01
Ø 59 -02
5.71 +0.1 -0.3
+2’
29°52´
4.71
Exhaust valve
1.10.7-2.10.01-
05; 02

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M20 c
Cylinder Head
- Deviations from true running valve shaft

The deviation from true running on the valve stem must not exceed 0.04 mm on the
measuring distance „S“ of 200 mm.
The deviation from true running on the valve cone must not exceed 0.02 mm.
For both measurements the valve stem must
lie in the measuring device at points A and B.
20 20
A B
Reuse of a valve stem is not possible if:

1. there is severe pitting on the bottom side of the
valve head (formation of so-called „paving stones“),
2. there are corrosion pits and mechanical

damages in the area of the valve stem, stem
transition, and valve head,
s
3. the limit for refinishing is exceeded.
4. In case of corrosive material wear of 2 % from the valve head diameter.

In case of high-temperature corrosion „S“ of 1.50 mm.

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M20 c
Cylinder Head
- Fitting of valve seat rings

1. Cool valve seat ring down to -195°C
(liquid nitrogen).
2. Insert inlet and exhaust valve seat rings.
3. When the valve seat rings are tight,
press them on with hydraulic device.
4. Check of the bearing surface „Y 2“,
between inlet valve seat ring and
cylinder head no air gap is admissible.
5. Check of the air gap „Y 1“, between
exhaust valve seat ring and cylinder
head. Admissible air gap 0.2+0.3 mm.
Pressure test: Cooling water spaces
Y1
10 bar for 8 min.
Y2
Valve seat rings
Maximum admissible dimension for refinishing the
exhaust valve seat ring: Recess Y must remain
palpable.
inlet valve seat ring: Minimum dimension „Z“ must not be less than 1mm by refinishing.
Refinishing is possible with MaK valve refacer or MaK valve seat milling device.
After grinding there shall be a bearing face of 30-50 % starting from the outside diameter.
5’
5’+
Z
30°
Ø59 + 0.2
Ø66 + 0.2
5’
5’+
20°
Ø59 + 0.2
Ø66 + 0.2
5’
5’+
30°
Y

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M20 c
Piston
- Tightening torques Mahle 1.10.7-26.70.00-01

The tightening torque for inserting the studs in the
piston crown is → M = 10 Nm
Tighten nuts with → M = 35 Nm
loosen nuts again and check the tightening torque for inserting
the studs with → M = 10 Nm
and tighten with → Dw = 50°
Check : At a torque of → M = 35 Nm
the nuts must not turn further.
- Tightening torques Mahle 1.10.7-26.70.00-02 / 03 / 04 / 05

The tightening torque for inserting the studs in the
piston crown is → M = 10 Nm
then tighten with → Dw = 80°
loosen nuts again and check the tightening torque for inserting
the studs with → M = 10 Nm

Molykote
Check gap size between piston crown and skirt → 0.04 - 0.09 mm
Screws not tightened.

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M20 c
Piston
Check : At a torque
of → M = 35 Nm
the nuts must not turn further.
Coat thread and contact surface of the nuts
with Molykote paste G-n.
Attention: In case of reinstallation replace studs if
projecting length of bottom support exceeds
71.3 mm.
71.3
- MHW 1.10.7-26.70.00-22 Fitting

specification
Insert fixing pin (spring cotter) into the piston
crown. Coat thread in the piston crown with
motor oil.
Coat thread of the stud with graphite paste,
insert it into the piston crown and tighten
smoothly with → M = 30 Nm
Spray piston crown and skirt with corrosion preventing oil. Grease the joint ring and insert
it torsionless into the piston skirt. Put the piston skirt on the piston crown. Grease the
spherical washers as well as the nut thread with graphite paste and tighten the nut until
you feel the first resistance.
Check gap size between piston crown and skirt at 4 points (each time shifted by 45° in
circumferential direction).
Nominal value → 0.06 ± 0.02 mm
Tighten nuts alternately in steps of → M = 10 Nm
up to → M = 50 Nm
and loosen again.
Check the tightening torque of the stud in the
piston crown with → M = 30 Nm
Tighten nuts until you feel the first resistance
and then alternately in steps of → M = 10 Nm
up to → M = 40 + 5 Nm

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M20 c
Piston
- Kolbenschmidt 1.10.7-26.70.00-07
Coat thread and contact surface with Molykote-Paste G-n-plus.
Tighten screws crosswise with → M = 24 Nm
Loosen screws again.

Pretighten screws with → M = 10 Nm
and tighten
with → Dw = 60°
Check: At a torque of → M = 19 Nm
further turning of the screws must not be possible.
Clearance between piston crown and piston skirt → 0.06 - 0.10 mm

Screws not tightened.
- Wear limit and clearances

pistons with 4 rings
Grooves Groove height Ring height Wear limit Limit clearance
1 5 +0.12 - 0.14 4.95 -0.010 - 0.025 5.60 0.65
2 5 +0.10 - 0.12 4.95 -0.010 - 0.025 5.60 0.65
3 5 +0.06 - 0.08 4.95 -0.010 - 0.025 5.60 0.65
4 6 +0.06 - 0.08 6.00 -0.010 - 0.025 6.50 0.50
pistons with 3 rings
Grooves Groove height Ring height Wear limit Limit clearance
1 5 +0.12 - 0.14 4.95 -0.010 - 0.025 5.60 0.65
2 5 +0.10 - 0.12 4.95 -0.010 - 0.025 5.60 0.65
3 6 +0.06 - 0.08 6.00 -0.010 - 0.025 6.50 0.50

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M20 c
Piston
- Piston rings gas oil operation

piston 1.10.7-26.70.00-01 / -02 / -03 / -04
ring groove ring
1 Rectangular ring 1.10.7-26.17.01-05.1 alternative -04.1
2+3 Compression ring 1.10.7-26.17.01-06.1
4 Oil scraper ring 1.10.7-26.17.01-03.1
piston 1.10.7-26.70.00-05 / -22

ring groove ring
2 Compression ring 1.10.7-26.17.01-06.1
3 Oil scraper ring 1.10.7-26.17.01-03.1
piston 1.10.7-26.70.00-07
ring groove ring
3 Oil scraper ring 1.10.7-26.17.01-03.1
- Piston rings heavy fuel operation

Piston 1.10.7-26.70.00-01 / -02 / -03 / -04
ring groove ring
1 Rectangular ring 1.10.7-26.17.01-04.1 rpl. -07.1
2+3 Compression ring 1.10.7-26.17.01-06.1
4 Oil scraper ring 1.10.7-26.17.01-03.1
piston 1.10.7-26.70.00-05 / -22

ring groove ring
1 Rectangular ring 1.10.7-26.17.01-04.1 rpl. -07.1
3 Oil scraper ring 1.10.7-26.17.01-03.1
piston 1.10.7-26.70.00-07
ring groove ring
1 Rectangular ring 1.10.7-26.17.01-07.1
3 Oil scraper ring 1.10.7-26.17.01-03.1
Piston 1.10.7-26.70.00-03 up to 170 kW/cyl. Piston 1.10.7-26.70.00-04/-05 190 kW/cyl.
Piston ring: 1.10.7-26.17.01-07.1 three-sided chromium-plated;
1.10.7-26.17.01.04.1 Chromium ceramic ring
Arrange the ring butts in longitudinal direction of engine alternately opposed. Fit piston
rings with marking upwards.
Removal
In order to avoid loosening of the cylinder liner during removal of the cylinder head or
subsequent turning, the cylinder liner has to be secured always in the crankcase by means of
the retainer. Before removing the piston the fire ring must be removed.

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M20 c
Connecting Rod
- Big end bearing

1. Tighten bolts 3 and 4 (bottom) with → M = 160 Nm
2. Tighten bolts 1 and 2 (top) with → M = 160 Nm
3. Tighten bolts 1 and 2 once more with → M = 160 Nm
4. Tighten bolts 3 and 4 with → M = 350 Nm
Tighten bolts 1 and 2 with → M = 350 Nm

Molykote
Bolts 1+2 = short + top

Bolts 3+4 = long + bottom
After tightening the big end bolts 1 and 2 to the final torque (350 Nm), tighten big end bolts 3
and 4 once more with the final torque (350 Nm) in order to avoid loss of pretension (settling
effect).
The final tightening torque corresponds to an angle of ratation of:

For bolts 1 + 2 at least 13°- 16°
For bolts 3 + 4 at least 17°- 19°
starting from the pretorque of 160 Nm
4
- Big end bearings
Together with the tool kit 2 tightening angle
gauges - one for the big end bolts 1-2 and
one for the big end bolts 3-4 -are supplied.
These tools serve for checking the tightening
angles stated above.
3
If after correct tightening of all big end bolts

the „minimum degrees“ are not reached, the
whole tightening procedure must be
repeated.
- Fitting of piston pin bush

Cool the piston pin bush down to ≤ -160° C and push it into piston pin boss, taking care
of the correct position of the oil bores. The lateral projection must be the same on both
sides. After reaching the normal temperature the piston pin bush has to be measured.
The reference dimension after shrinking-in in

cooled state is Ø → 90.09 mm
+ 0.06
- Maximum tolerance between piston pin and piston pin bush

The maximum tolerance between piston pin
and piston pin bush is → 0,170 mm

m
M20 c
Connecting Rod
- Measurement of the gap

1. Pretighten bolts 3 and 4 with 160 Nm.
2. Measure dimension „X 1“ by means of a slide gauge.
3. Tighten bolts 1 and 2 twice successively in the sequence 1-2/1-2 with 160 Nm.
4. Tighten bolts 3-4/1-2 with 350 Nm.
5. Measure dimension „X 2“
.
„X 1 - X 2“ = gap → 0.45 - 0.65 mm
0.35 mm
Limit value →
1+2
X1 2 Reference size A
X
3+4
Reference size B
- Reference dimension of the big end bearings after correct tightening
Size „ A“ → 152.140 +0.05

mm
Size „ B“ → A + 0.04 +0.06

mm

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M20 c
Liner
- Nominal size Ø (original size)

→ 200.00 +46
mm
- Wear limits
Wear and tear value → 0.80 mm
Max. ovality → 0.25 mm

- Wedge shape
Height → 6.00 mm
Depth * → 0.03 mm
Wedge-shaped indentation across the entire circumference, beginning at TDC 1st piston ring.
- Canyon
Max. number → 3
Length → 6.00 mm
Total width → 3.00 mm
Individual deep blow-through ducts in the area of the 1st piston ring (TDC).
- Score
Number → 3
Length → 140.00 mm
Depth → 0.03 mm
Hard vertical, linear friction marks.

- Pocket
Number → 3
Length → 45.00 mm
Width * * → 15.00 mm
Depth * → 0.02 mm
Areal, irregular indentations.

m
M20 c
Liner
wedge shape pocket score TDC 1st ring canyon
- Fire ring
Modern engines are equipped with fire rings in the liners.
In this case the broader joint ring is used between liner and cylinder head.
Old joint ring — 11.8 mm
New joint ring — 15.0 mm
Both joint rings are 5 mm thick, the oversize rings are 6 mm thick.
- Dismounting of fire ring (without groove)

1. Turn piston top edge below the 1
fire ring.
2. Place dismounting device on the

piston so that the recess lies inside
the fire ring.
3. Slightly tighten the dismounting

device by turning spindle nut - 1 -.
4. Press fire ring out by turning the

piston up.

m
M20 c
Liner
- Removal of the fire ring (with groove)

(old and rare device)
1. Clean groove in the
fire ring.
2. Turn piston downwards
until pressure ring - 1 -
of the removing device
with circlip - 2 - can
be inserted. The
circlip must rest
safely in the groove of
the fire ring. 3
3. Put the liner supports
- 3 - on a useless
joint ring and tighten Useless joint
ring as a
by hand with the protection of
cylinder head nuts. 2 the sealing
The useless joint ring 1 surface.
serves as a protction
of the sealing surface in
the liner. The liner must
not be lifted when
turning it out.
4. Turn the piston carefully
upwards, permanently
observing the fire ring and the liner.
- Mounting liner
The liner must slide into the cylinder crankcase by its own weight. Attention must be paid
to the correct installation position, i.e. mark - 1 - must point to flywheel side in longitudinal
direction. On the cooling water distributing ring there is a cast lug - 2 - serving as
alignment aid.
X
X

m
M20 c
Crankshaft
- Crankshaft bearing
The tightening torque for inserting the studs - 1 - is → M = 400 Nm
Molykote
1. Tighten round nuts for main bearings - 2 - steadily by hand.
2. Tighten hexagon screws (lateral screws) - 3 - alternately. (start at control side)
2.1 → M = 100 Nm
2.2 → M = 300 Nm
2.3 → M = 480 Nm
alternative tightening: (alternately in 3 steps)

2.1 → M = 100 Nm
30°
2.2 → M = 280 Nm
2.3 → Dw = 30°
Molykote
camshaft side exhaust gas side
3 3
3. Lengthen main bearing screws with → P = 750 bar

and tighten nuts with a pin.
This corresponds to a tightening angle of → Dw = 135°
or 3 holes (stated for additional checking). Molykote
Check: Reduce pressure to → P = 700 bar
Loosening the nuts must not be possible any more.
The pressure must remain constant if the pump is not operated, otherwise faulty tightening.
Tighten main bearing nuts always in one operation.
Tighten value for hydraulic jack area: 54.8 cm 2

m
M20 c
Crankshaft
- Marking
Bearing caps and bearing shells are marked on S1 S2
camshaft side with the relative cylinder numbers,
counted from flywheel side. The parts must not
be mixed up.
1
- Located and normal main bearings 2
are identical; for axial fixing on bearing 2 (located
main bearing) thrust washers - 1 - with clamping
pins - 2 - are mounted on bearing cap - 3 -.
End clearance „S“ → = S 1 + S 2
If the main bearings cannot be loosened with

P = 750 bar, pressure increase by 50 bar to 3
800 bar is possible. Further increase of pressure
involves the risk that the thread will expand and
the nuts will jam. The bottom shells of the normal
main bearings have a guide groove on camshaft side. The located main bearing cap
(bearing 2) has a fixing pin on exhaust gas side.
The bearings with maximum stress are:

6 cyl. engine bearing 4
- Measurement of the gap
1. Remove lateral bolts of the
main bearing and loosen
those of the adjacent main KS KA
bearings by several turns
of thread.
2. Loosen both main bearing
nuts of one bearing pocket
in one operation.
3. Tighten main bearing nuts
by hand alternately and
steadily until the joint
faces of the bearing
shells just touch.
4. Check the projecting
length of the bearing shell by
measuring the gap between
cylinder crankcase and
bearing cap on camshaft and exhaust gas sides.
Gap K = K A + K s

m
M20 c
Crankshaft
- Normal and located main bearing

gap → 0.50 - 0.80 mm
limit value → 0.40 mm
- Located main bearing

end clearance → 0.23 + 0.165 mm
limit clearance → 0.60 mm
- Crank web deflection

cylinder 1 -9
other cylinders 4 / -6
- Counterweight
Tighten screws with → M = 450 Nm
Molykote
6 cyl. engine 12 counterweights

crankpin 1 2pcs.
crankpin 2 1pc., left side *
crankpin 3 1pc., right side *
crankpin 4 2pcs.
crankpin 5 2pcs.
crankpin 6 1pc. left side *
crankpin 7 1pc. right side *
crankpin 8 2pcs.

crankpin 1 2pcs.
crankpin 2 1pc., left side *
crankpin 3 without counterweight
crankpin 4 2pcs.
crankpin 5 2pcs.
crankpin 6 2pcs.
crankpin 7 without counterweight
crankpin 8 1pc., right side *
crankpin 9 2pcs.
* = seen from camshaft side

m
M20 c
Gear Train
- Gear wheel on crankshaft

Mount the gear wheel on the crankshaft cone
by hand.
Increase pressure to → P = 500 bar
with the hydraulic device and press
gear wheel into its final position.
The slide-on distance is :for 1.10.7-25.30.00-01 → 7.2 -2.7 mm.

for 1.10.7-25.30.00-02 → 9.1 -2.95 mm.
Dimension 186 +0.1 mm from front edge gear wheel to the end of crankshaft.
Engine start at the earliest 2 hours after pressure relief.
Hydraulic
connection
186 +0.1

m
M20 c
Gear Train
- Mounting of crankshaft gear wheel

Turn cylinder 1 into TDC-position (both pressure connections in the crankshaft are upright
one on top of the other). Slide on the crankshaft gear wheel so that the blind hole (without
thread) is located to the left, distorted by approximately 30° (vertically above the
pressure connections is now a taphole). Measure the distance from crankshaft end to
gear wheel. Put on the adapter ring and take care that the positioning pin enters into the
blind hole. Screw in the threaded rod. The two locking screws are inside the holes.
Remove the locking screw of bore „Z“, screw in the pressure pipe and fasten it. Slide on
the pressure ring with the smooth side towards the gear wheel. In the pick-up pocket
there is the pressure pipe. Screw the nut on the threaded rod and tighten it by hand
After connecting the pressure pump apply a pressure of approximately 500 bar.
Slide the gear wheel on the cone up to the limit stop using a ratchet and the nut. The slide-
on distance on old engines (mounting gear wheel on crankshaft variant -01) is
4.5 mm -7.2 mm and on new engines (mounting gear wheel on crankshaft variant -02).
6.1 mm -9.1 mm
Lower the pressure to 0 bar. Do not dismount the hydraulic pump so that the oil may flow
off. After at least 20 minutes the device can be removed.
Fasten the oil splasher on the gear wheel.
Mount the end cover. If there are no dowel pins (old engines) this cover must be centered
with a dial gauge.
Dismounting proceeds in reverse order. Please take care that there is a distance of
approximately 1 mm between pressure nut and pressure ring.
Connection „S“ for the flywheel M8 thread for

Connection „Z“ for the gear wheel fixation of oil
splasher
Blind hole
M30 for the

threaded rod
Connection
„S“
Connection
„Z“

m
M20 c
Gear Train
- Intermediate gear wheel mounting

Tighten screws - 1 - for the locking plate with → M = 60 Nm
Molykote
old design new design
spacer spacer
1
1
thrust rings
2
X gap size
min.:0.30
max.:1.40
thrust rings
Thrust washers of the new type are glued in.
The adhesion surface areas must be grease-free. oil
grooves
The oil grooves of the thrust washers must show to the gear wheel.

m
M20 c
Gear Train
- Mounting of intermediate gear wheel

The locking plate - 2 - must rest firmly in the groove root of the intermediate gear wheel
axle - 3 -.
Attention! When exchanging the O-ring on the intermediate gear wheel axle take care
that the intermediate gear wheel remains in the meshing of camshaft and crankshaft gear.
Otherwise, there is the risk of misaajusted timing data.
- Lub. oil injectors for the gear drive

Tighten hollow screws with → M = 40 Nm
- Backlash
Crankshaft gear - intermediate gear wheel → 0.20 - 0.40 mm
intermediate gear wheel - camshaft gear → 0.20 - 0.40 mm
- Intermediate gear wheel

End clearance → 0.20 - 0.80 mm

m
M20 c
Gear Train
- Camshaft gear wheel

Tighten screws - 1 - with → M = 85 Nm
Molykote

Molykote
5.8 +1

m
M20 c
Governor Drive
- Governor drive gear

Tighten fixing screws - 1 - for → M = 60 Nm
governor drive gear with
Molykote
Tighten castellated nut for fixing the helical gear

wheel - 2 - with → M = 30 Nm
and tighten further to the next split pin hole. Molykote
- Backlash
Small governor drive gear (helical gear wheel) -big
governor drive gear (helical gear wheel) → 0.15 - 0.20 mm
- End clearance
End clearance - 3 - between governor console and
coupling bush → 0.10 - 0.30 mm
Between the big governor drive gear (helical gear wheel)

and the end cover there must be a clearance - 4 - of → 0.30 - 0.75 mm
Wenn it’s nessecary to change the bushes - 5 - und - 6 - in the engine block, so observe
the measurements in the sketch. Oil the bushes a little before fitting. Use no Molykote.
5 3

m
M20 c
Camshaft
- Camshaft bearing
Tighten fixing screws for the camshaft bearings with → M = 30 Nm
- Vibration damper for camshaft

1.10.7-31.40.00-01- replaced by 1.10.7-31.40.00-05
(6M20)
Molykote
4 screws M12 x 1,5 X 55 ISO 4762
1.10.7-31.40.00-02 replaced by 1.10.7-31.40.00-06

(8M20 / 2 vibration dampers)
Molykote
4 screws M12 x 1,5 X 60 ISO 4762
1.10.7-31.40.00-03 replaced by 1.10.7-31.40.00-07

(9M20 / 3 vibration dampers)
Tighten screws - 1 - and - 2 - with → M = 60 Nm
Molykote
1 = 4 allen screws M12x1,5x130 ISO 4762 8.8-A3C
2 = 2 allen screws M12x1,5x45 ISO 4762 8.8-A3C
Take care of
the bore
position

m
M20 c
Camshaft
- Tightening torques camshaft

Tighten allen screws - 1 - with → M = 100 Nm
Molykote
Tighten screws - 2 - for flange - 3 - with → M = 100 Nm
Molykote
for allen screws - 4 - see → gear train
1 1 2
- Mounting camshaft
During every assembly of the camshaft take care that a cylindrical pin - 2 - is inserted up
to stop position in the camshaft flanges - 1 -. The cylindrical pin must always be inserted
near the flange code number - 3 - acc. to the following schedule:
6 cyl. Flange code 8 cyl. Flange code 9 cyl. Flange code
Part number Part n u m b e r Part number
1 4 1 5 1 1
2 2 2 2 2 1
3 3 3 3 3 2
4 4 4 4 4 3
5 5 5 5 5 4
6 6 6 6 6 4
7 7 7 3
8 8 8 2
1 9 1

m
M20 c
Lower Valve Drive
The end clearance between two adjacent bearing

brackets is → 0.10 - 0.20 mm
13 0.10 - 0.20
Mounting instruction
At the junction points of the rocking lever shafts no air is admissible. When the bearing
caps are loosened, the rocking lever shafts must be pushed together from both sides.

m
M20 c
Fuel Injection Pumps
The tightening torque for inserting

the studs is → M = 40 Nm
Molykote
Tighten fastening nuts with → M = 50 Nm
Molykote
- Injection pump 0.00.6-43.12.00-72 type: DSFP 1M

torques are also valid for 0.00.6-43.12.00-97
2 2
mixed oil drain
stop
lub. oil inlet

regulating
distance 36 mm

m
M20 c
- Injection pump 0.00.6-43.12.00-79 type: DSFP 1MW

torques are also valid for 0.00.6-43.12.00-98
Tighten screw - 1 - and - 2 - with → M = 45 Nm
Tighten screw - 3 - with → M = 25 Nm
Tighten baffle screw - 4 - with → M = 50 Nm
Insert countersunk screws - 5 - with Loctite 243

and tighten with → M=5 Nm
4 4
mixed oil drain
stop
lub. oil inlet

regulating
distance 36 mm
5
3

m
M20 c
- Injection pump 0.00.6-43.12.00-92 type: DSFP 1MW

Tighten screw - 1 - and - 2 - with → M = 45 Nm
Tighten screw - 3 - with → M = 25 Nm
Tighten baffle screw - 4 - with → M = 90 Nm
Insert countersunk screws - 5 - with Loctite 243

and tighten with → M=5 Nm
This fuel injection pump is replaces the fuel injection pump 0.00.6-43.12.00-79
4 4
mixed oil drain
stop
lub. oil inlet

regulating
distance 36 mm
5
3

m
M20 c
- Fuel distributing and collecting pipe

expansion pipes / old design
Tighten screws - 1 - to fuel injection pump
alternately with → M = 50 Nm
M12x DIN 931
- Fuel distributing pipe for fuel injection pump variants -79 and -92
sliding pipes
Circlip - 1 - must be removed before the plug-in pipes can be axially shifted and removed.
1
2

m
M20 c
- Dismounting / mounting
During dismounting / mounting attention must be paid that the appertaining distance steel
plates are not removed.
If for any reason removal of the distance steel plates is necessary, they have to be
marked with the relevant cylinder number.
The thickness of the distance steel plates for each cylinder is stated in the acceptance test
record.
Commencement of Firing TDC
delivery
- Check of commencement of fuel delivery
1. Dismount the injection pump delivery
valve.
2. Mount dial gauge with extension. Position of
3. Turn engine so that roller rests on commencement of
the base circle of cam and the TDC delivery
mark is abt. 45 ° before the dea
center indicator.
4. Set dial gauge to „0“, turn engine in direction of rotation
until the indication on the gauge is 5 mm for 170 kW/cyl. and
4 mm for 190 kW/cyl.
5. Check the dimension on the flywheel from TDC mark to dead center indicator.
(1° = 8.8 mm)
As to the commencement of fuel delivery please look into the testbed record.
setting
1. Place the gauge with measuring device on a level support by means of the
adjusting bush (dimension = 44.2 mm) and set gauge to „0“.
2. Insert measuring device into the injection pump bore in the engine housing
and read value on the dial gauge (roller on cam base circle).
3. Indicated value = thickness of the distance steel plates.
The distance steel plates are used for setting the pre-stroke.
available sizes:
2.00 mm 2.10 mm 2.20 mm 2.30 mm 2.40 mm 2.50 mm
2.60 mm 2.70 mm 2.80 mm 2.90 mm 3.00 mm
adjustment of the commencement of fuel injection with built up injection

pump
The roller of the pump drive of cylinder 1 is located on the base circle. Remove the con-
necting piece and the pressure-balancing delivery valve from the injection pump. Fix a dial
gauge on the pump (touches the plunger). Turn the engine in sense of rotation until the
dial gauge indicates 5 mm (old engines; 170 kW/cyl.) (4 mm: new engines; 190 kW/cyl.).
Screw the pressure pipe into the respective taphole of the camshaft and tighten it. Mount
hydraulic pump and apply a pressure of approximately 900 - 1000 bar. Turn the
crankshaft to the respective commencement of fuel injection (see test bed record).
remark:
If necessary, the camshaft ought to be fixed (is normally not necessary with built up
injection pumps). After mounting crankshaft gear wheel and flywheel check the TDC-
position of the first cylinder in view of correct flywheel markings! If necessary, new
markings must be applied.

m
M20 c
Sundries
- Regulating shaft
Setting instruction
1. Connect shaft of the control stand with the regulating shaft by means of coupling.
Do not yet remove assembly pin for the shaft fixing.
2. Shift control rack of the injection pump at cyl. 1 so that coincidence of line mark and
indication is reached.
3. In this position clamp articulated lever fast, keeping the distance of 0.5 mm
between control rack head and articulated lever.
Tightening torque → M = 25 Nm
Molykote
4. Repeat procedure on all remaining cylinders acc. to instructions of points 2 and 3.
5. Remove assembly pin for the shaft fixing in the control stand.
6. Check easy motion of control linkage.
7. Seal articulated lever with lead.
assembly
During assembly insert the regulating shaft with grease (do not use Molykote).
regulating shaft
Tighten screw 1 - for the bearing bracket with → M = 60 Nm
Molykote
0.20 Clearance

m
M20 c
Sundries
Tighten screws - 1 - and - 2 -

with → M = 25 Nm
Molykote
- Fuel indicator 1
Cam - 1 - must be adjusted in a way that in stop
position the center of the fuel indicator is in line with
the stamped punch mark - 2 -.
2
Ensure the clearance of the swing range of the cam
disc. Rework cam disc if necessary. 3

m
M20 c
Sundries
- Cooling water distributing pipe

Tighten screws (M16 x 100 8.8 -A3C) - 1 - with → M = 130 Nm
Molykote
Tighten screws - 2 - (if onhand) step by step with

1. step → M = 20 Nm
2. step → M = 50 Nm
Molykote
Tighten screws - 3 - (if onhand) with → M = 15 Nm

Molykote
1 2 3

m
M20 c
Opposite Side of Coupling
- With and without power take-off with vibration damper

Coat thread and screw head surface with Molykote
Pretighten fixing screws - 1 - with → M = 100 Nm

Molykote
With the fixing screws pump impeller carrier and gear wheel for lub. oil pump drive are fixed
at the same time.
The vibration damper is connected to the lub. oil system of the engine. Each spring pack
has its own supply bore. When checking the vibration damper the oil bores have to be
checked for free passage.
1
All tightening torques on this page are valid for
the flanged shaft mounting with or without
power take-off.

m
M20 c
Pump Carrier
- Pump carrier plate

Coat thread and screw head surface with Molykote.
Tighten screws M 12 with → M = 60 Nm
Molykote
Tighten screws M 8 with → M = 25 Nm

Molykote
- Pump carrier plate

Align pump carrier plate - 1 - over centering
of the pump gear carrier - 2 -, and screw it
at the cylinder crankcase with sealing
compound and pin it.
- Cooling water pump

Tighten screw for fastening the
gear wheel with → M = 60 Nm
Molykote
- Fuel feed pump

Molykote
- Lub. oil pump

Molykote
m
M20 c
Pump Carrier
- Pump mounting
lub. oil pump mounting, suction and pressure
pump as well as cooling water pump mounting
HT and LT circuit and fuel feed pump mounting
1. Check contact reflection on the
appertaining pump gear wheel cone by
blue paste. Only a contact reflection
displaced to the thick end is admissible.
2. Heat gear wheel of the
1
- lub. oil pump up to 90°C - 100°C
- cooling water pump and
fuel feed pump up to 120°C - 130°C
2
- sea water pump up to 100°C - 110°C
(The other values of the sea water pump are
like the values of the cooling water pump.)
above temperature of the pump shaft and mount
it firmly on the pump cone up to stop position.
(for example: When there’s a temperature of 20°C
on the pump shaft of a fuel feed pump, the gear wheel
has to be heatet to 140°C - 150°C.)
The cone faces must be grease-free and dry.
3. Fit and tighten screw - 1 - with washer - 2 -.
slide-on distance lub.oil pumps — 0.33 - 0.41 mm
slide-on distance cooling water pumps — 0.29 - 0.32 mm
slide-on distance fuel feed pumps — 0.44 mm
- Backlashes
lub. oil pump mounting
backlash → 0.20 - 0.47 mm
fuel feed pump mounting

0.24 - 0.50 mm
backlash →
cooling water pump mounting

backlash → 0.20 - 0.47 mm

m
M20 c
Flywheel Mounting
- Mounting - disassembly
Turn crankshaft into TDC cyl. 1. Insert flywheel vertically suspended into transport hole
and push it on the crankshaft cone until contact is reached. Mount device, apply a
pressure
of → P = 1300 bar
and press flywheel into the final position.
Final position means flush with end of crankshaft. The

slide-on distance is : 15.5 -2.8 mm and 16.5 -3.05 mm.
1. Turn crankshaft to TDC cyl. 1. (In this position the

projecting screw heads at the gear wheel on
crankshaft are pointing to the respective
pickup pockets on the flywheel).
2. Insert flywheel vertically suspended into

transport hole dia. 50 mm and push it on the
crankshaft cone until contact is reached.
3. Press flywheel into final position by means of

device and oil hydraulic mounting.
4. Final position, as shown, flush with end of

crankshaft.
5. Realease device earliest 24 h after bleeding

the oil hydraulic mounting.
Motor start-up earliest 72 h after removing
the holding device.
When dismounting a flywheel, a mark should be applied on

the flywheel and on the crankshaft in order to avoid an
incorrect fitting.
- Gear rim on flywheel for pneumatic starter

Molykote

m
M20 c
Flywheel Mounting
- Flywheel variants
The following flywheels are in use.
Flywheel 1.10.7-73.10.01-
Var. old slide - on distance replaced by var. slide-on distance

- 03 15.5 -2.8 mm - 09 16.5 - 3.05 mm
- 04 15.5 -2.8 mm - 10 16.5 - 3.05 mm
- 05 15.5 -2.8 mm - 11 16.5 - 3.05 mm
- 06 15.5 -2.8 mm - 12 16.5 - 3.05 mm
- 07 15.5 -2.8 mm - 14 16.5 - 3.05 mm
- 13 16.5 - 3.05 mm
- 15 16,5 - 3,05 mm
- 16 16,5 - 3,05 mm
- 17 16,5 - 3,05 mm
- 18 16,5 - 3,05 mm
The flywheel variants are stamped at the front side of the flywheels, for instance „1-09“.

m
M20 c
Flexible Flange Connection
- Flexible flange connection for generator gp engine
8 M 20
Tighten screws - 1 - M16 as frictional resistance with → M = 170 Nm

oil
Tighten screws - 2 - M24 with → M = 675 Nm
oil
oil
9 M 20
Tighten screws - 1 - M18 as frictional resistance with → M = 235 Nm

oil
oil
oil
1
6 M 20 8 M 20
values for older variants with only 2 different

kinds of srews
(not shown)
Tighten screws M14x160-10.9 as frictional

resistance with → M = 190 Nm
oil
Tighten screws M16x50-10.9 with → M = 250 Nm

oil

m
M20 c
Charge Air Cooler
- Mounting
Tighten screws - 1 - M = 60 Nm
with →
Molykote
Tighten screws - 2 - M = 60 Nm
with →
Molykote
1
4
Applicable to coupling side and opposite side.

When mounting the charge air cooler care is to be taken that the screws - 3 -and - 4 - are
alternately tightened in small steps.
First tighten screws - 4 - firmly and only then screws - 3 -.

m
M20 c
Charge Air Cooler
- Cleaning
In the acceptance test record the differential pressure before / after charge air cooler is
stated. When the value has reached the 1.5-fold, cleaning has to be carried out.
- Dismounting
Remove cooling water inlet and outlet pipes. Loosen screws - 1 - and - 3 - and withdraw
the charge air cooler from the casing.
Fitting in reverse order, taking care of perfect fit of the sealing shims.

m
M20 c
Exhaust Gas Manifold
Tighten all M12 screws with → M = 60 Nm

Rivolta G.W.F.
Tighten screws - 1 - in 2 steps with
1. step → M = 60 Nm
2. step → M = 110 Nm
Rivolta G.W.F.
Insert all screws with paste Rivolta G.W.F.
max. 5 mm
Attention ! Recession
Take care of the correct screw length. High nut
A projection is inadmissible.
Spray all connecting straps with graphite or

Molybdaen spray before mounting.
No gaskets between expansion joints and exhaust gas
pipes. Mount all expansion joints in direction of arrow.
→ M = 200 Nm
Tighten screws - 2 -with
Rivolta G.W.F.

m
M20 c
Generator GP-Engine
- Attachment engine and generator

Tighten the torques for the fixing screws step by step.
step 1 → 20 %
step 2 → 60 %
step 3 → 100 %
Tighten bolts class of strength 8.8 - M10 - with → M = 40 Nm

oil
oil
oil
oil
oil
oil
oil
- Sealing surfaces
Daub sealing surfaces of engine and base frame with sealing material Hylomar. Lay
GORETEX - sealing towards the engine inside; overlap cutting points approx. 200mm.

m
M20 c
Flexible Mounting
- Assembly
casting resin: cean unmachined top plates
steel chocks: machine top plates
1. Align engine with jacking screws:

Vertically approx. 3.30 mm above the gear shaft (gearbox with vertical shaft
offset) and horizontally approx. 3.10 mm above the gear shaft (gearbox with
horizontal shaft offset).
in true alignment diagonally to the gearbox
axial coupling axially relieved
1 2
2. Bore top plates for bonded rubber rail fixation - 1 - and - 2 - (max. Ø 20 mm).
3. Mount bonded rubber

3
rails - 1 - and - 2 -
and tighten nuts - 3 -
with → M = 160 Nm
Oil
5 4

m
M20 c
Flexible Mounting
4.1 Casting resin: Cast the bonded rubber rails according to the instructions of the
producer of the casting resin (casting resin must not touch the rubber). Lower the
engine after curing the casting resin (relieve jacking screws completely). Statical
spring deflection approx. 2.90 mm.
4.2 Steel chocks: Measure distance between plate and bonded rubber rails.
Manufacture steel chocks and insert them. Lower engine according to 4.1.
5. Fix bonded rubber rails with screws - 4 - and washers - 5 - on top plate.

Oil
6. Fit stopper - 6 - according to the order (are marked with numbers) at the engine
mount and tighten with nuts - 7 -
with → M = 160 Nm
Oil
Weld pipe - 8 - centrically to the stopper.
11 adjust 1.5
mm during
assembly
10
7
12
9
15

m
M20 c
Flexible Mounting
7. Bore top plates for tie rod - 9 -. (The tie rods are to be provided by the shipyard)
8. Mount tie rod - 9 -. Adjust the vertical clearance of 1.50 mm between

stopper - 6 - and disk - 10 - and fix
locknut - 15 - with → M = 1400 Nm
Secure it with Loctite 242 blue.
Jam locknut - 11 - with → M = 1400 Nm
Oil
9. Fit in rubber lining - 12 -.
10. Further statical spring deflection (lowering of the engine after 24 h)

approx. 0.40 mm.
The engine is then roughly aligned with the gear shaft. (Gearbox with vertical
shaft offset).
11. At operating temperatures the engine stands approx. 0.50 mm higher than the
gearbox.
(Due to growth of bonded rubber rail, engine, gearbox, and foundation).
The flexible coupling is designed for this, i.e. further re-alignment is not necessary.
13
14
Tighten nuts - 13 - and - 14 - with → M = 160 Nm

Nuts - 13 - .Oil
Secure nut - 14 – with Loctite 242 blue.
Secure jacking screws after chocking with spacer tubes between screw head and
engine mount against unintentional tightening and loosening.
Tighten all bolts M16 of the flexible mounting with → M = 200 Nm

Oil

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M20 c
Firing Sequences - Valve Timing Values
firing sequences
6 cyl. engine clockwise 1-3-5-6-4-2
counterclockwise 1-2-4-6-5-3
8 cyl. engine clockwise 1-2-4-6-8-7-5-3
counterclockwise 1-3-5-7-8-6-4-2
9 cyl. engine clockwise 1-2-4-6-8-9-7-5-3
counterclockwise 1-3-5-7-9-8-6-4-2
valve timing values

old output 170 KW / cyl.
Exhaust valve opens 60 ° ca. before BDC
Exhaust valve closes 55 ° ca. after TDC
Inlet valve opens 55 ° ca. before TDC
Inlet valve closes 40 ° ca. after BDC
new output 190 KW / cyl.
Exhaust valve opens 40 ° ca. before BDC
Exhaust valve closes 45 ° ca. after TDC
Inlet valve opens 45 ° ca. before TDC
Inlet valve closes 5 ° ca. after BDC
ca. = crankangle

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M20 c
Dimensions and Weights
designation length mm width mm height mm weight kg
crankcase without studs

6 cyl. engine 3190
8 cyl. engine 4040
9 cyl. engine 4530
Crankshaft
6 cyl. engine 2428 Ø 374 730
8 cyl. engine 3088 Ø 374 1000
9 cyl. engine 3415 Ø 374 1100
counterweight 22
gear wheel on crankshaft 82 Ø 273 16
liner variation 01 + 02 597 Ø 277 60

liner from variation 04 to 08 594,4 Ø 277 60
piston with connecting rod 60.5
cyl. head compl. 121
cyl. head 85.5
camshaft bearing 72 Ø 190 1.5
big end bearing 69 Ø 161 1,1
cooling waterdistribution
housing 602 328 170 43.5
injection pump 123 133 342 18
camshaft element 330 Ø 142 19
camshaft bearing 40 Ø 160 1.3
gear wheel on camshaft 65 Ø 533 105
intermediate gear wheel 23

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M20 c
Dimensions and Weights
designation length mm width mm height mm weight kg
housing for charge air

cooler 210
charge air cooler 877 540 440 170
lub. oil cooler 82
pump carrier plate 78
starter 34
flywheel, generator 217 Ø 1005 320
flywheel, propeller 204 Ø 1005 307
gear rim on flywheel 38 Ø 1015 44
vibration damper 151 Ø 620 263
lub. oil pump 404 230 245 34
cooling water pump 354 270 335 42

m
M20 c


Engineer's Handbook - M20

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Engineer's Handbook - M20

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Caterpillar confidential: yellow

Table of Contents .......................................................................... 2

Engine Block .................................................................................. 8

Cylinder Head ................................................................................. 9

Edition Service Document of Page

Connecting Rod ........................................................................... 23

Gear Train ..................................................................................... 31

Governor Drive ............................................................................ 36

Edition Service Document of Page

Lower Valve Drive ....................................................................... 39

Fuel Injection Pumps ................................................................... 40

Opposite Side of Coupling ......................................................... 48

Pump Carrier ................................................................................ 49

Flywheel Mounting ...................................................................... 51

Flexible Flange Connection ....................................................... 53

Edition Service Document of Page

Charge Air Cooler ........................................................................ 54

Exhaust Gas Manifold ................................................................. 56

Generator GP-Engine ................................................................. 57

Flexible Mounting ........................................................................ 58

Firing Sequences - Valve Timing Values ................................... 61

Dimensions and Weights ............................................................ 62

Edition Service Document of Page

The following values serve for judgment on possible failures:

2. Fuel rack reading

3. Lubricating oil t inlet engine t oil cooler inlet

4. Fresh water t inlet engine t outlet engine

t inlet charge air cooler t outlet charge air cooler

5. Charge air temperature t before cooler t before engine

6. Exhaust gas temperature t after cylinder t after turbocharger

7. Lub. oil pressure

8. Fresh water pressure

9. Charge air pressure after charge air cooler

10. Differential pressure at the charge air cooler

Edition Service Document of Page

- Engine data - Engine operating data

stroke = 300 mm temperatures

bore = 200 mm lub. oil

speed, rpm = 900 - 1000 engine inlet 60 - 65 ° C

main bearing temperature rise 10 - 14 ° C

inside Ø = 180 mm fresh water circulation cooling

outside Ø = 190 mm engine outlet 60 - 70 ° C

big end bearing temperature rise 6 - 12 ° C

inside Ø = 152 mm charge air

outside Ø = 161 mm engine inlet 45 - 60 ° C

valves, inlet and exhaust pressures

length = 336 mm lub. oil 4.0 - 4.5 bar

shaft Ø = 14.05 mm fresh water circulation cooling

valve head Ø = 66 mm with min. 4 mWs 2.5 - 6.0 bar

valve guide fuel pressure before injection

details for rated engine output and nominal

Numbers of teeth on camshaft gear wheel = 80 teeth.

N = (F x 60 x 2) / 60 (Rpm) F = (N x Z) / (2 x 60) (Hz)

Edition Service Document of Page

- Tightening torques for screw plugs

Tighten screw plugs M22x1,5 with → M = 180 Nm

Tighten screw plugs M26x1,5 with → M = 200 Nm

Tighten screw plugs M33x2 with → M = 200 Nm

Tighten screw plugs M42x2 with → M = 300 Nm

Tighten screw plugs M52x2 with → M = 400 Nm

- Crank case cover 1

Tighten the screws - 1 - for the